Telecommunications chassis and card

ABSTRACT

A chassis and associated telecommunication circuit card are disclosed. The chassis has heat dissipation and flame containment features while accommodating a high density of the circuitry cards. Embodiments include an inner housing with a double-layer middle floor dividing the chassis into top and bottom chambers. Each layer has partially aligned slots, and an air gap is provided between the two layers. Embodiments also include a double-layer mesh cover with an air gap existing between the two mesh layers. Projections and grooves are provided on the inner surfaces of the inner housing to receive circuit cards having a guide on one edge and a fin on another. The circuit card includes conductor structures such as multiple board layers with paired and segregated conductors. The circuit card also includes some components positioned to cooperate with the ventilation features of the chassis and includes some components chosen for low-power consumption or reduced flammability.

RELATED APPLICATIONS

This application is a continuation-in-part of the application with Ser.No. 09/795,656 entitled TELECOMMUNICATIONS CHASSIS AND CARD WITH FLAMESPREAD CONTAINMENT filed on Feb. 28, 2001.

TECHNICAL FIELD

This invention relates to chassis for holding telecommunications cardssuch as repeater circuits. More specifically, the present inventionrelates to chassis and cards with structures for flame spreadcontainment and/or high card density.

BACKGROUND

It is desirable for a chassis for holding telecommunication circuitcards to support a high density of cards, yet the chassis musteffectively dissipate heat developed during operation while containingthe spread of flames should a fire be imposed within the chassis. Thecards installed in the chassis perform electrical operations, such assignal transception and amplification that generate a significant amountof heat. Typically, a chassis is installed in a rack that containsseveral other chassis stacked above and below. The heat and flames thatmay develop within a chassis in the rack have the potential to harmcircuit cards housed in the chassis above and below the chassis wherethe heat and/or flames emanate from, and the flames should be containedto avoid damaging cards in the other chassis.

The chassis must also provide external protection for the circuit cardsit houses. Thus, the chassis cannot freely expose the circuit cards toareas outside the chassis when attempting to dissipate heat and flames.Additionally, the chassis must provide a structural interconnection thatmaintains electrical continuity between the circuit cards and externaltransmission mediums such as copper wires or fiber optic cables whilefacilitating insertion and removal of the cards. A sufficient structuremust be used to facilitate this circuit card modularity, which furtherlimits the chassis' ability to provide outlets for heat and flames.

Additionally, to reduce the chassis size for a given number of circuits,the circuit card density must be increased. Increasing circuit carddensity is difficult not only due to heat dissipation and potentialflame spread, but also because of electromagnetic noise that must becontained. Generally, increasing circuit card density involves employingsmaller cards, and smaller cards require higher component density withinthe cards. Achieving effective heat dissipation with adequate flamespread and electromagnetic noise containment may even be more difficultfor smaller card designs with higher component densities.

Thus several factors must be accounted for in the chassis and carddesign. Chassis designs with large interior spaces for directing heatand flames away from circuit cards may be undesirable because thechassis may become too large when accommodating a high density ofcircuits. Chassis designs with open exteriors for directing heat andflames away from the circuit cards may be undesirable because thecircuit cards may not be sufficiently protected from externalities suchas falling objects or heat and flames spreading from a chassispositioned above or below in the rack. Card designs that are relativelylarge require a larger chassis to house the same quantity of cards.

Thus, there is a need for a chassis and card design whereby the chassismay contain a high density of readily removable circuit cards whileproviding effective heat dissipation and flame and electromagnetic noisecontainment.

SUMMARY

The present invention provides a chassis and card design that mayaccommodate a high density of readily removable circuits while providingheat dissipation and flame and electromagnetic noise containmentfeatures. Ventilation and containment structures are employed to directheat away from internal circuitry while preventing flames from spreadingwithin the chassis. Additionally, chassis designs of the presentinvention may provide exterior features that establish protection fromexternalities and prevent the harmful spread of heat and flames tochassis or other equipment stacked above or below. Card designs of thepresent invention may provide conductor structures for containingelectromagnetic noise and/or individual components placed in locationsfor coordination with the ventilation structures of the chassis.

The present invention may be viewed as a chassis for housing repeatercards. The chassis includes an inner housing with vertical sidewalls, afirst surface, and a second surface. The first surface and the secondsurface have a first and second row of openings. The chassis alsoincludes one or more repeater cards positioned between the first surfaceand the second surface. The one or more repeater cards has a DC—DCconverter and a transceiver with the DC—DC converter being positionedbetween a first opening of the first row of the first surface and afirst opening of the second row of the second surface at least partiallyaligned with the first opening of the first row of the first surface.The transceiver is positioned between a first opening of the second rowof the first surface and a first opening of the second row of the secondsurface at least partially aligned with the first opening of the secondrow of the first surface.

The present invention may also be viewed as a repeater card. Therepeater card includes a printed circuit board having a ground layer anda power layer separated by a dielectric with the ground layer having achassis ground plane, a logic ground plane, and a first channel groundplane, and with the power layer having a logic power plane and a firstchannel power plane. The logic ground plane substantially overlaps withthe logic power plane and the first channel ground plane substantiallyoverlaps with the first channel power plane. A DC—DC converter ismounted to the printed circuit board and electrically linked to thelogic ground plane, the logic power plane, the first channel groundplane, the first channel power plane, and the chassis ground plane. Atransceiver is mounted to the printed circuit board and electricallylinked to the DC—DC converter, the logic ground plane, the logic powerplane, the first channel ground plane, and the first channel powerplane.

DESCRIPTION OF THE DRAWINGS

FIG. 1A is a top front perspective view of a chassis loaded withrepeater cards

FIG. 1B is a bottom front perspective view of the chassis loaded withrepeater cards.

FIG. 2 is a top front perspective view of an empty chassis with cardslot covers in place.

FIG. 3A is a top view of the empty chassis.

FIG. 3B is a front view of the empty chassis.

FIG. 3C is a right side view of the empty chassis.

FIG. 4A is a top view of the loaded chassis.

FIG. 4B is a front view of the loaded chassis.

FIG. 4C is a right side view of the loaded chassis.

FIG. 5A is a bottom rear perspective view of the loaded chassis.

FIG. 5B is a top rear perspective view of the loaded chassis.

FIG. 6A is another top view of the loaded chassis.

FIG. 6B is a rear view of the loaded chassis.

FIG. 6C is a left side view of the loaded chassis.

FIG. 7 is a side view of the empty chassis with the outer sidewallremoved.

FIG. 8 is an exploded top rear perspective view of the empty chassis.

FIG. 9 is a top view of the empty chassis with the top cover layers andtop surface of the inner housing removed.

FIG. 10 is an exploded top front perspective view of the empty chassis.

FIG. 11A is a top view of the empty inner housing of the empty chassis.

FIG. 11B is a cross-sectional front view of the empty inner housing ofthe empty chassis along lines A—A of FIG. 11A.

FIG. 11C is a partial top front perspective view of the empty innerhousing of the empty chassis.

FIG. 12 is a top front exploded perspective view of the inner housing ofthe chassis loaded with three cards.

FIG. 13 is a bottom front exploded perspective view of the inner housingof the chassis loaded with three cards.

FIG. 14 is a top rear exploded perspective view of the inner housing ofthe chassis loaded with three cards.

FIG. 15 is a bottom rear exploded perspective view of the inner housingof the chassis loaded with three cards.

FIG. 16A is a top front perspective view of the backplane of thechassis.

FIG. 16B is a top view of the backplane of the chassis.

FIG. 16C is a front view of the backplane of the chassis.

FIG. 16D is a right side view of the backplane of the chassis.

FIG. 17A is a partial top front perspective view of a card mounted to afloor surface of the inner housing of the chassis.

FIG. 17B is a top rear perspective view of a card mounted to a floorsurface of the inner housing of the chassis.

FIG. 17C is a top front perspective view of a card mounted to a floorsurface of the inner housing of the chassis.

FIG. 17D is a partial top rear perspective view of a card mounted to afloor surface of the inner housing of the chassis.

FIG. 18A is a partial bottom front perspective view of cards partiallyinstalled relative to a ceiling surface of the inner housing of thechassis.

FIG. 18B is a partial top front perspective view of cards partiallyinstalled relative to a ceiling surface of the inner housing of thechassis.

FIG. 18C is a partial bottom rear perspective view of cards partiallyinstalled relative to a ceiling surface of the inner housing of thechassis.

FIG. 18D is a partial top rear perspective view of cards partiallyinstalled relative to a ceiling surface of the inner housing of thechassis.

FIG. 19A is a top view of a repeater circuit card.

FIG. 19B is a left side view of the repeater circuit card.

FIG. 19C is a front view of the repeater circuit card.

FIG. 20A is a top front perspective view of the repeater circuit card.

FIG. 20B is an exploded top right perspective view of the repeatercircuit card.

FIG. 20C is an exploded top left perspective view of the repeatercircuit card.

FIG. 21 is an exploded top rear perspective view of a heat baffle.

FIG. 22 is top front perspective view of a rack holding multiple chassisand the heat baffle.

FIG. 23A is front view of a rack holding multiple chassis and the heatbaffle.

FIG. 23B is a right side view of a rack holding multiple chassis and theheat baffle.

FIG. 24A is top front perspective view of a rack holding multiplechassis and the heat baffle positioned for installation.

FIG. 24B is right side view of a rack holding multiple chassis and theheat baffle positioned for installation.

FIG. 25 is a side view of the circuit board of the circuit card showingthe relative position of the components of a repeater circuit.

FIG. 26 is a schematic of alarm circuitry of the repeater circuit.

FIG. 27 is a schematic of transceiver configuration circuitry of therepeater circuit.

FIG. 28 is a schematic of power supply circuitry of the repeatercircuit.

FIG. 29 is a view of a ground conductor layer of the printed circuitboard supporting the repeater circuit.

FIG. 30 is a view of a power conductor layer of the printed circuitboard supporting the repeater circuit.

FIG. 31 is a view of a component layer of the printed circuit boardsupporting the repeater circuit.

DETAILED DESCRIPTION

Various embodiments of the present invention will be described in detailwith reference to the drawings, wherein like reference numeralsrepresent like parts and assemblies through the several views. Referenceto various embodiments does not limit the scope of the invention, whichis limited only by the scope of the claims attached hereto.

FIGS. 1A and 1B show a loaded chassis 100 in accordance with oneembodiment of the present invention. The chassis includes verticalsidewalls including right sidewall 104. A top mesh cover 102 isincluded, and this cover as well as other mesh covers discussed belowtypically are perforated rolled steel wherein the perforations provideair passages. An exemplary mesh cover is made of aluminum and has 63% ofits surface occupied by relatively small and densely positioned airpassages, but other materials and air passage percentages for the meshcovers are also applicable. Cover 102 may have angular portions 102′. Aswith all surfaces of the chassis 100, the rolled steel may be used andmay have a clear chromate plating to reduce electromagneticinterference. The chassis 100 also has a bottom mesh cover 116 thatcovers the bottom of the chassis 100.

A backplane 106 having external connectors 108 is included forestablishing electrical communication between the circuit cards 110housed by the chassis 100 and external cabling passing through thechassis rack. The external connectors 108 may be a terminal block, butother connector types are suitable as well. The cards typically have amounting screw 110′ that secures the card to the chassis 100. Thechassis 100 includes mounting flanges 112 and 114 for installation ofthe chassis 100 in a rack. A ground connector 109 is included forproviding chassis ground.

FIGS. 2-3C show an empty chassis 100. The empty chassis 100 has cardslot covers 111 that cover each card slot reserved for a circuit card110. The card slot covers are held in place by a screw 111′ that issecured to the chassis 100. FIGS. 3A and 3C also show a backplane cover118 that is more clearly shown in FIGS. 5A and 5B. The backplane cover118, typically made of lexan, prevents exposure of circuit leads andpins on the backside of the backplane 106.

FIGS. 4A-C show a loaded chassis 100. The loaded chassis 100 is filledwith circuit cards 110 held in place by the fastener 110′. The circuitcards 110 have a finger 175 extending from a faceplate 174. The finger175 provides a handle for an operator to grip when inserting or removingthe circuit cards 110 from the chassis 100. The finger 175 and circuitcard 110 are shown and described in more detail below.

FIGS. 5A-6C illustrate the chassis 100 with the focus shifted to therear portion where the backplane 106, external connectors 108, andbackplane cover 118 are located. The vertical sidewall 105 is alsovisible in these views. Also visible in these views is a backplane powerconnection 106′ that generally mates to a power connection in a rack toprovide power to circuit cards 110 through internal connectors discussedbelow and receive alarm signals generated by the circuit cards 110.

FIG. 7 shows a side view of the chassis 100 with the sidewall 104removed. As can be seen, the chassis 100 consists of several layersincluding the top mesh cover 102, an air gap 103, a second mesh coverlayer 120 and 122, a top surface 132, a middle floor 134, and the bottomsurface 138. The second mesh cover layer 120 and 122 overlays the topsurface 132, and the top mesh cover 102 overlays the second mesh coverlayer 120 and 122. The air gap 103 is established by ridges 130 formedin the top surface 132 that create recessed portions 131 in the topsurface. Cover projections 123 are provided to maintain spacing betweencover layer 102 and the underlying mesh strips 120 and 122. Thesidewalls 104, 105, the middle floor 134, and the top surface 130 andbottom surface 138 are held together by fasteners 132′, 142′, 140′, and138′.

The middle floor includes a top plate 142 and a bottom plate 140separated by an air gap 143. The top plate 142 overlays the bottom plate140. Similar to air gap 103, ridges 158 in the bottom plate 140 createrecessed portions 141 that establish the air gap 143 in the middle floor134. The bottom mesh cover 116 directly underlays the bottom surface138. The relationship of these layers relative to the inner housing 101is further illustrated in FIG. 8.

FIG. 8 shows the exploded view from a top rear perspective of thechassis 100. The underlying mesh cover layer 120 and 122 is shown as twoindividual strips of mesh material. These two strips 120 and 122 liewithin the recesses 131 formed in the top surface 132 between the ridges130. Inner sidewalls 126 within inner housing 101 are also visible inFIG. 8. These inner sidewalls 126 create compartments 125 and 127 withina bottom chamber 125′ and top chamber 127′, respectively, within theinner housing 101. Internal connectors 124 located on the inner side ofbackplane 106 are also visible and are used to mate with the circuitcard 110. The airgap 143 in the middle floor 134 is also shown.

FIG. 9 shows a top view of the chassis 100 with the top cover 102,second cover layer strips 120 and 122, and the top surface 132 of theinner housing 101 removed. The top plate 142 is visible and openingsincluding slots 154 are visible. The bottom plate 140 is partiallyvisible through the slots 154 where the bottom plate's slots 150 are notin perfect alignment due to shape, position, or size with the slots 154of the top plate 142. As described below, these slots 150 and 154 permitheat from circuit cards 110 in bottom chamber 125′ to be dissipatedwhile containing flames emanating from the bottom chamber 125′.

FIG. 10 shows an exploded view of the chassis 100 with the inner housingintact from a top front perspective. The internal connectors 124 areshown. The internal connectors fit within the compartments 125 and 127and the circuit cards 110 slide into the inner housing 110 from thefront. A connector on the circuit card 110 then slides into engagementwith the internal connector 124. Generally, one card corresponds to oneinternal connector 124. As shown, seven cards fit into a singlecompartment 125 or 127. Also shown in FIG. 10 are cover projections 123on the mesh cover layer formed by the individual mesh strips 120 and122. The cover projections 123 assist in maintaining the air gap 103formed between the top mesh cover 102 and the mesh strips 120, 122.

FIGS. 11A-11C show the inner housing 101 from several views. In FIG. 1A,looking down onto the top surface 132, a slight misalignment between theslots 154 of the top plate 142 and be seen because top plate 142 isvisible through slots 160 in the top surface 132 of the inner housing101. As discussed above, misalignment of the slots may result fromdifferent sizes or shapes of the slots in one surface relative to thoseof another or may result from slots of the same size and shape nothaving a common position in one surface relative to the slot position inanother surface. As shown, slots 144 in the bottom surface 116 and slots154 in the top plate 142 have the same size, shape and common positionand are aligned but misalignment is introduced by slots 150 in bottomplate 140 because slots 150 in the bottom plate have a different size.Similarly, slots 150 in the bottom plate and slots 160 in the topsurface have the same size, shape, and common position and are aligned,but slots 154 in the top plate have a different size and therefore,introduce misalignment. This misalignment facilitates the flamecontainment while allowing heat dissipation to occur.

FIG. 11B shows a front cross-sectional view taken through line A—A ofFIG. 11A. The air gap 143 can be seen in this view. Also visible is theside-to-side alignment of openings 144 and 154 in the bottom surface 116and the top plate 142, respectively. The side-to-side alignment ofopenings 150 and 160 in the bottom plate and the top surface,respectively, can also be seen. Misalignment between openings 144 and150, between openings 150 and 154, and between 154 and 160 is visible aswell.

FIGS. 12 through 15 show exploded views of the inner housing 101 fromtop front, bottom front, top rear, and bottom rear perspectives,respectively. Several circuit cards 110 are shown in installed positionsrelative to the top plate 142 or the bottom plate 140. Inner side walls126 include ribs 126′ that are sized to fit within ridges 130 of the topsurface 132 or 158 of the bottom plate 140. Ribs 126′ prevent flamesfrom spreading over the inner sidewall 126 through the ridge 130 or 158and into adjacent compartments and further support the middle floor 134and the top surface 132. Mounting tabs 138′ on the bottom surface 138and mounting tabs 142′ on the top plate 142 extend vertically upward tocontact the vertical sidewalls 126, 104, 105 and hold them in place.Similarly, mounting tabs 132′ on the top surface 132 and mounting tabs140′ on the bottom plate extend vertically downwardly to contact thevertical sidewalls 126, 104, 105 and hold them in place.

As shown, the inner housing 101 provides eight compartments includingfour top chambers and four bottom chambers, with each chamber holding upto seven circuit cards 110. Thus, for the chassis 100, the inner housing101 shown can accommodate fifty-six circuit cards 110. It is to beunderstood that the number of chambers spanning the width of chassis 100may vary from the number shown, as may the number of chambers that spanthe height. Four are shown spanning the width and two are shown spanningthe height only as an example. Furthermore, it is to be understood thatthe number of circuit cards per compartment may vary and that seven areshown only as an example.

To hold each circuit card, the bottom surface 138 is provided withprojections 146 shown as lances that hold guides on the circuit cards110. The top plate 142 of middle floor 134 also has projections 152 tohold guides on the circuit cards 110 installed above the middle floor134. To provide guidance for the top of the circuit cards 110 installedin the bottom chamber 125, a bottom plate 140 of the middle floor 134has grooves or fin slots 156 running from the front edge where the cards110 are inserted to the back edge where the backplane 106 is located.The leading edge of the top plate 142 of middle floor 134 is alsogrooved or slotted to align with the grooves or fin slots 156 of thebottom plate 140. The top surface 132 of the inner housing 101 also hasgrooves or fin slots 148 that provide guidance to the top of the circuitcards 110. The separation 143 in the middle floor 134 aids in theability to provide grooves or fin slots 156 on the bottom side whileproviding projections 152 on the top side.

The ventilation slots 144 of the bottom surface 138 allow air passing upthrough the bottom mesh cover 116 to pass between the circuit cards 110in the bottom chambers 125. Slots 150 of the bottom plate 140 at leastpartially align with the slots 144 in the bottom surface 138 and airpassing up between the circuit cards 110 located in the bottom chambers125 may pass through the slots 150 in the bottom plate 140. The topplate 142 has slots 154 that are at least partially aligned with theslots 150 of the bottom plate 140 and air passing up through the slots150 in the bottom plate pass through the separation and then through theslots 154 in the top plate 142.

After air has passed through the middle floor 134, it may rise betweencircuit cards 110 installed in the top chambers. Slots 160 of the topsurface 132 allow the air to pass through the top surface 132. The meshcover created by the mesh strips 120 and 122 allows the air to pass intothe separation between the mesh strips 120, 122 and the top mesh cover102. Air then may pass through the top meshcover 102.

Thus, air can be successfully channeled through the bottom cover 116 upthrough the chassis 100 and out through the top cover 102. When chassisare stacked, air passing out the top mesh cover 102 of the lower chassis100 passes into the next chassis 100 through the bottom mesh cover 116.This continues until air passes out of the top mesh cover 102 of thehighest stacked chassis 100. Heat generated by the circuit cards 110 ischanneled up through each chassis passing through the small separationbetween cards 110 until it exits out of the rack.

The slots 144 may be provided in several rows on the bottom surface 138,and three rows are shown including a first row 224, a second row 226,and a third row 228. A solid area 210 on the bottom surface 138 may beincluded, such as between the first row 224 of slots and a first edge234 of the bottom surface 138. The third row 228 of slots of the bottomsurface 138 may be positioned between the second row 226 of slots and asecond edge 240 that is opposite the first edge 234 of the bottomsurface 138.

Similarly, the slots 150 and 154 of the middle floor 134 may bepositioned in several rows, such as the three-row configuration shown.The slots of first row 218 of the middle floor 134 at least partiallyoverlap with the slots of the first row 224 of the bottom surface 138.The slots of second row 220 of the middle floor 134 at least partiallyoverlap with the slots of the second row 226 of the bottom surface 138.The slots of the third row 222 at least partially overlap with the slotsof the third row 228 of the bottoms surface 138.

The middle floor 134 may also include a solid area 208 that ispositioned between the first row 218 of slots and a first edge 323 ofthe middle floor 134. The third row 222 of slots of the middle floor 134may be positioned between the second row 220 of slots and a second edge238 opposite the first edge 232 of the middle floor 134. The solid area208 at least partially overlaps with the solid area 210 of the bottomsurface 138.

The slots 160 of the top surface 132 may be positioned in several rowsas well, including the three adjacent rows that are shown. The slots ofthe first row 212 of the top surface 132 at least partially overlap withthe slots of the first row 218 of the middle floor 134. The slots of thesecond row 214 of the top surface 132 at least partially overlap withthe slots of the second row 220 of the middle floor 134. The slots ofthe third row 216 of the top surface 132 at least partially overlap withthe slots of the third row 222 of the middle floor 134.

The top surface may also include a solid area 206 that is positionedbetween the first row 212 of slots and a first edge 230 of the topsurface 132. The third row 216 of slots may be positioned between thesecond row 214 of slots and a second edge 236 of the top surface 132opposite the first edge 230. The solid area 206 at least partiallyoverlaps with the solid area 208 of the middle floor 134.

The spacing between the top plate 142 and the bottom plate 140 of themiddle floor 134 diffuses flames emanating from circuit cards 110 in thebottom chamber 125′ before they may pass into the top chamber 127′.Likewise, mesh strips 120, 122 and the separation between the meshstrips 120, 122 and the mesh cover 102 diffuse flames emanating fromcircuit cards 110 in the top chamber 127′. Additionally, the bottom meshcover 116 of the next chassis up in the rack assists in diffusing anyflames not fully diffused by the mesh cover layers in the top of thechassis 100. Inner side panels 126 create barriers to flames escaping tothe sides of the chambers so that the flame becomes trapped within achamber between the two side panels 126, the floor, and the ceiling.

In the event of a fire, material on a given circuit card burns, soot isformed and rises. The soot may collect in the perforations of the meshcovers to clog the holes. This clogging effect assists in choking thefire. Furthermore, the bottom cover 116 catches material as it wouldfall from a burning card. The mesh strips 120, 122 are positioned sothat they overlay the first and second rows of slots of the top surface132, middle floor 134, and bottom surface 138. Thus, the third row ofslots of the top surface 132, middle floor 134, and bottom surface 138are not covered by the mesh strips 120, 122 but only by the mesh cover102. As a result, a less resistive pathway is created through up throughthe third row and additional ventilation is provided through the thirdrow 228, 222, and 216.

The opposite effect is created by providing the solid areas of the topsurface 132, middle floor 134, and bottom surface 138. The overlappingsolid areas 206, 208, and 210 prevent upward air flow. As a result, airis channeled from the front edges 234, 232, and 230 toward the third row228, 222, and 216 and eventually up through the mesh cover 102.Electrical components, such as large capacitors that tend to burn but donot produce significant amounts of heat may be positioned between theoverlapping solid areas so that less ventilation is provided acrossthem.

Electrical components that do produce significant amounts of heat may bepositioned between the overlapping rows of slots so that ventilation isadequate. Electrical components that may produce heat and aresusceptible to some burning may be positioned between the overlappingfirst rows or between the overlapping second rows so that ventilation isprovided, but mesh strips 120, 122 provide additional flame diffusion.Layout of a repeater circuit card as it relates to the slots and solidareas of the chassis 100 is discussed below with reference to FIGS. 17Aand 25.

FIGS. 16A-16D show the backplane. As previously discussed, the backplane106 provides several internal connectors 124 sized to engage anelectrical connector on the circuit card 110. The connectors 124generally provide signals to the circuit card 110 and/or receive signalsfrom it. The connectors 124 pass signals between the card and theexternal connectors 108. The external connectors are sized to engageelectrical cables passing up through a chassis rack.

As shown, fourteen external connectors 108 are provided and fifty-sixinternal connectors 124 are provided. Thus, each external connectorcommunicates with four internal connectors 124. A power connector 106′is also located on the backplane and is sized to engage a powerconnector in the chassis rack. The power connector 106′ provides powerto each of the internal connectors 124 that then channel the electricalpower to the circuit card 110.

FIGS. 17A-17D show several views of the repeater circuit card 110installed relative to the bottom surface 138 of the inner housing 101 ofthe chassis 100. The cards 110 mount in the same fashion to the topplate 142. The repeater circuit card 110 has a guide 164 that isgenerally perpendicular to the card 110 and that fits between theprojections 146 of the bottom surface 138 and the projections 152 of themiddle floor 134. The guide 164 includes slots 166 that partially alignwith the slots 144 in the bottom surface. Likewise, the slots 166partially align with the slots 154 in the top plate 142 of the middlefloor 134. Thus, the air passing through the bottom surface 138 and/orthrough the middle floor 134 passes through the slots 166 in the guide164 on each circuit card 110 and then between each circuit card 110 andon through the area above.

As discussed above and shown in detail in FIG. 17A, electricalcomponents such as a capacitor 242 that do not produce significant heatbut are susceptible to burning may be positioned on specific locationsof the card 110. For example, the capacitor 242 may be positioned suchthat when the card 110 is fully installed in the chassis 100, thecomponent 242 is positioned between solid areas such as above the solidarea 210 of the bottom surface 138 and below the solid area 208 of themiddle floor 134.

Components that do produce heat such as a DC—DC converter 244 or atransceiver 246, may be positioned on the card 110 such that when thecard is fully installed in the chassis 100 the components 244, 246 arepositioned between overlapping rows of slots. As shown, the component244 is positioned between the first row 224 of the bottom surface 138that overlaps with the first row 218 of the middle floor 134. Thecomponent 246 is positioned between the second row 226 of the bottomsurface 138 that overlaps with the second row 220 of the middle floor134. The circuitry including DC—DC converter 244 and transceiver 246 ofa repeater circuit card 110 are discussed in more detail below.

The circuit card 110 has a connector 168 that mates with card edgeconnector 124 on the backplane 106 of the chassis 100 once the card 110has been fully inserted into a card position in the inner housing 101. Acard faceplate 174 abuts the bottom surface 138 of the inner housing 101and may provide a connection to the middle floor 134 or top surface 132to lock the card 110 in place. In addition to the guide 164 aligning thecard 110 in conjunction with the projections 146, 152 within a cardposition in the inner housing 101, fin 170 also assists by guiding thetop of the card 110 when introduced into a groove or fin slot 148, 156.

FIGS. 18A-18D show various views of repeater cards 110 with a positionrelative to grooves or fin slots 148 in recessed areas 131 defined byridges 132 in the top surface 132 of the inner housing 101. As the card110 is being inserted into a card position in the inner housing 101, thefin 170 must align with the groove 148 for the card to fitperpendicularly relative to the top surface 132. A perpendicularorientation of the card relative to the top surface 132 is used in thisembodiment for the guide 164 of the card 110 to seat on the middle floor134, or bottom surface 116 and fit between the guide projections 146,152. A perpendicular orientation also permits the card connector 168 toeasily slide into and out of the backplane connector 124.

The card 110 is guided by the groove 148 as it is inserted, and once theguide 164 reaches a projection 146, 152, the guide 164 also assists inmaintaining the card 110 within a designated card position. Once thecard is fully inserted, the card connector 168 maintains electricalconnection to the internal backplane connector 124 and the cardfaceplate 174 abuts the top surface 132.

FIGS. 19A-19C show various plan views and FIGS. 20A-20D show variousexploded views of a T1 repeater card 110. It is to be understood thatthe chassis 100 may accommodate circuit cards 110 having functionalityother than that of a repeater circuit. The repeater card 110 has a mainprinted circuit board 172 housing various electrical circuitry 172′.Typically with a repeater circuit, the card 110 will include atransceiving device to receive and reconstruct a signal having a datacomponent and a clock component. The repeater circuitry 172′ alsousually includes amplification. This circuitry 172′ may generate asignificant amount of heat that must be dissipated by the chassis 100.

As shown, the connector 168 received by internal backplane connector 124is an extension of the printed circuit board 172. The guide 164 withslots 166 that fits between the projections 146, 152 attaches to thebottom edge of the printed circuit board 172 and is positionedtransversely relative to the circuit board 172. The guide is typicallymade of sheet metal. The fin 170 that fits within the groove 148,attaches to the top edge of the printed circuit board 172 and lies in aplane parallel to that of the printed circuit board 172. The fin 170 isalso typically made of sheet metal.

Faceplate 174 attaches to a front edge of the repeater card 110. Thefaceplate typically has light emitting diodes (LEDs) 177 that allowvisual inspection of the circuit card's operation. As discussed, thefaceplate 174 may establish a fixed connection to the middle floor 134or the top surface 132 with fastener 110′ to hold the card 110 withinthe inner housing 101. A generally forward positioned finger 175extending away from the faceplate 174 in a direction opposite to theprinted circuit board 172 may be integrated into the faceplate 174 toassist in the insertion and removal of the card 110 from the chassis100.

FIG. 21 illustrates a heat baffle 177 that may be utilized by anembodiment of the present invention. The baffle 177 has a hood portion179. The hood portion 179 has a sloped portion 176 and triangular sidepanels 188. The triangular side panels 188 have mounting flanges 190that rest on the surface of a chassis 100. The baffle 177 also has abase portion 181 having a floor 182 and a face 192. The base portion 181lies directly over the top mesh layer 102 and the hood portion 179directly overlays the base portion 181 with the face 192 being fixed tothe sloped region 176 with clips 184 that pass through slots 186 topinch the face 192 to a lip 189 extending from the sloped region 176.The heat baffle 177 may be utilized by inserting the baffle betweenchassis 100 stacked in a rack. As heat and/or flames rise from the topcover 102 of a chassis 100, the heat and/or flames are diverted out thefront or back of the rack depending upon the orientation of the baffle177.

The hood portion 179 of the baffle 177 is typically a solid sheet ofrolled sheet metal. Thus, heat and flames cannot permeate the slopedsurface 176 and are redirected. However, the base portion 181 istypically a mesh material such as permeated rolled sheet metal thatallows heat to pass through while diffusing flames. The hood portion isfixed to the rack holding the chassis 100 with mounting flanges 178 and180. The mounting flanges 178, 180 are shown as being mounted to a firstposition used where the front of the chassis 100 extends beyond a railof the rack. Where the chassis 100 has a front edge flush with themounting rail of the rack, the flanges 178, 180 attach so that they areflush with the front edge of the baffle 177.

FIG. 22 shows a top front perspective view of a rack 194 holding severalchassis 100 with a heat baffle 177 installed. The heat rises through thechassis 100 as previously discussed and exits out the top cover 102 ofthe top chassis and is redirected to the rear of the rack 194 by theheat baffle 177. The typical chassis includes a base 196 with a frontportion 198. Two vertical siderails 200 and 202 are included and arefixed to the base 196. Each chassis 100 and the heat baffle 177 slidesinto position between the siderails 200 and 202 and mounting flanges112, 114 of the chassis 100 and the flanges 178, 180 of the baffle 177abut the rails 200, 202. Cable bars 204 extend from the siderails 200,202 and wrap behind each chassis 100 and baffle 177.

FIGS. 23A and 23B show a front and right side view, respectively, of therack 194 holding several chassis 100 with the heat baffle 177 installed.As shown, the heat baffle 177 is oriented with the face 192 directed tothe rear of the rack 194. The front edge of the heat baffle 177 is flushwith the front edge of the chassis 100, and the rear edge of the heatbaffle 177 slightly overhangs the rear edge of the chassis 100 toprevent heat and/or flames from curling down directly into the backplaneFIGS. 24A and 24B show a top front perspective view and a right sideview, respectively, of the rack 194 with the baffle 177 positioned forinstallation. The baffle 177 slides into the rack 194 above the top-mostchassis 100 and rests on the top cover 102 of the top-most chassis 100.The flanges 178, 180 (shown unattached) are attached to the baffle 177at the front edge so that when the baffle 177 is inserted into the rack,the front edge of the baffle 177 is flush with the front edge of thechassis 100 when the flanges 178, 180 contact the siderails 200, 202, ascan be seen in FIG. 22.

FIG. 25 shows a side view of a repeater circuitboard 172 of a card 110suitable for installation in the chassis 100. The repeater circuit board172 has several components positioned on the board 172 in relation tothe solid areas, rows of slots, and mesh strips of the horizontalsurfaces of the chassis 100. The repeater circuit board 172 includespower supply capacitor 242, DC—DC converter 244, and transceiver 246previously discussed. The board 172 has LEDs 262, 264, and 266 thatprovide external visual indications of the repeater circuit's operation.Other components of the board 172 include but are not limited to relays248, 250, and 252, a programmable logic device (PLD) 268, multi-positionswitches 254 and 256, an oscillator 286, and isolation transformers 258,258′, 260, and 260′. These components and their functions are discussedin more detail below.

The capacitor 242 is positioned such that solid areas of the chassis 100are above and below to prevent ventilating the capacitor 242. The solidareas direct air toward the rear of the board 172 past the DC—DCconverter 244 and transceiver 246 with some air passing up through thefirst row and second rows of slots and the remainder passing up throughthe less restricted third row of slots. The DC—DC converter 244 may be amodel that is highly flame resistant to further enhance the flamecontainment of the chassis 100. An epoxy encased DC—DC converter 244such as the Ericsson PFK 4611SI is suitable. A monitor jack, which mightordinarily be placed between the LEDs 264 and 266, is absent in theembodiment shown to reduce the material on the board 172 that issusceptible to burning.

FIG. 26 shows the alarm circuitry 271 of the repeater circuit board 172.The alarm circuitry 271 controls the LEDs 262, 264, and 266. Duringnormal operation, the LEDs 262, 264, and 266 are one color, such asgreen, to indicate normal operation. The power LED 262 turns red if thelogic power plane 272 loses voltage from the output of the DC—DCconverter 244. This occurs due to relay 252 changing state in responseto the loss of logic power thereby causing voltage received directlyfrom the backplane connector 168 to activate the red diode of LED 262instead of the green diode.

The channel A LED 264 and channel B LED 266 are electrically connectedto the PLD 268 and to a logic ground plane 270. The PLD 268 receivespower from the logic power plane 272 and receives control signals fromthe transceiver 246. When a channel is operating normally, the PLD 268causes the green diode of the LED to illuminate.

If the transceiver 246 detects that channel A has no signal, then LOS0line passing from the transceiver 246 to the PLD 268 is triggeredcausing the PLD 268 to light the red diode along with the green diode ofLED 264 to create a yellow illumination. If the transceiver 246 detectsthat channel B has no signal, then LOS1 line passing from thetransceiver 246 to the PLD 268 is triggered causing the PLD 268 to lightthe red diode along with the green diode of LED 266 to create a yellowillumination. If either channel has a loss of signal, then a minor alarmsignal is generated and provided through the backplane connector 168 byrelay 250 changing state due to a control signal from the PLD 268. Theminor alarm line is electrically linked to a chassis ground plane 274.

If the transceiver 246 detects that it has failed, then the DFM linepassing from the transceiver 246 to the PLD 268 is triggered causing thePLD 268 to light the red diode and turn off the green diode of LEDs 264and 266 to create a red illumination. A major alarm signal is alsogenerated and provided through the backplane connector 168 by relay 248changing state due to a control signal from the PLD 268. The major alarmline is electrically linked to the chassis ground plane 274 as well withcoupling capacitors.

The PLD 268 and relays 248, 250, and 252 may be selected so as tominimize power consumption and reduce the amount of heat being generatedby each circuit board 172 in the chassis 100. The Atmel model ATF16V8BQLPLD draws only 100 milliwatts when active and is a suitable PLD forcontrolling the relays 248 and 250 and LEDs 264 and 266. The NAIS TX-Srelay draws only 20 milliwatts when active and is a suitable relay forcontrolling the LED 262 and the major and minor alarm signals.

FIG. 27 shows the transceiver circuitry located on the board 172. Thetransceiver 246, such as the Level One model LXT332, is electricallyconnected to the logic power plane 272 and the logic ground plane 270.The transceiver is also electrically linked to a channel A power plane276, a channel A ground plane 280, a channel B power plane 278, and achannel B ground plane 282. Each channel has its own power and groundplane to avoid cross-talk and to avoid electrical noise from the powersupply circuit of FIG. 28 and chassis 100.

The transceiver 246 is electrically linked to an oscillator 286 that iselectrically connected to the logic power plane 272 and logic groundplane 270. The oscillator 286 provides a reference frequency signal tothe transceiver 246. The transceiver 246 is also electrically connectedto two multi-position switches 254 and 256. Each multi-position switchcontrols the line build-out function of the transceiver 246 for one ofthe channels.

The multi-position switch 254, 256 may be user adjusted to provide aconnection between the logic power plane 272 and various pins of thetransceiver 246. The transceiver 246 then determines the signal leveland signal shape for the output signal of a channel based on which pinsreceive the logic power plane voltage. The signal level and signal shapevaries depending upon the length of cable used to carry the outputsignal. The longer the cable, the stronger the output signal and themore its shape is altered from the shape desired at the other end of theoutput signal cable. For example, if a square wave is desired at theother end, then as cable length increases the output signal must havemore overshoot and a greater amplitude due to the cable's impedanceattenuating and rounding-off the signal.

The transceiver 246 receives its input signals for each channel from thebackplane connector 168 through an isolation transformer. Channel Ainput signal passes through isolation transformer 260, and channel Aoutput signal passes through isolation transformer 260′. Channel B inputsignal passes through isolation transformer 258, and channel B outputsignal passes through isolation transformer 258′. As shown in FIG. 25,the input isolation transformer 260 and output isolation transformer260′ of channel A are contained in one unit. Similarly, the inputisolation transformer 258 and output isolation transformer 258′ ofchannel B are contained in another unit.

FIG. 28 shows the power supply circuitry. The backplane connector 168receives −48V DC power and provides it through the board 172 to theDC—DC converter 244. The −48V line and the −48 V return line are linkedby the capacitor 242 to eliminate ripple. These lines are also coupledto the chassis ground plane 274. The DC—DC converter 244 outputs avoltage that is electrically connected to the logic power plane 272, thechannel A power plane 276, and the channel B power plane 278. The DC—DCconverter 244 has a return that is electrically connected to the logicground plane 270, the channel A ground plane 280, and the channel Bground plane 282. Ferrite beads are used to isolate each power planeconnected to the DC—DC converter 244 and each power plane is AC coupledto each ground plane.

FIG. 29 shows a ground layer of the circuit board 172. The ground layerincludes the chassis ground plane 274 that extends around the periphery288 of the circuit board 172 and is electrically connected to thechassis ground provided through the chassis ground connector 109 of thechassis 100. The chassis ground plane 274 surrounds the logic groundplane 270, the channel A ground plane 280, and the channel B groundplane 282. The chassis ground plane 274, logic ground plane 270, channelA ground plane 280, and channel B ground plane 282 are copper sheetsthat are isolated from each other within the single ground layer of theprinted circuit board 172.

FIG. 30 shows a power layer of the circuit board 172 that is adjacent tothe ground layer and separated from it by a dielectric layer. The powerlayer includes the logic power plane 272, the channel A power plane 276,and the channel B power plane 278. The logic power plane 272substantially overlaps with the logic ground plane 270 of the groundlayer. The channel A power plane 276 substantially overlaps with thechannel A ground plane 280. Likewise, the channel B power plane 278substantially overlaps with the channel B ground plane 282. Thisarrangement minimizes electrical noise and cross-talk.

FIG. 31 shows a component layer of the circuit board 172. The electricalcomponents previously discussed are typically mounted to the componentlayer. The transceiver 246 is mounted in transceiver area 294. Theisolation transformers 258, 258′, 260, and 260′ are mounted intransformer areas 296 and 298. It is generally desirable to minimize thedistance between the isolation transformer areas 296, 298 and thetransceiver area 294. A distance of one and one-third inches or less issuitable.

Also located on the component layer are chassis ground pads 290 and 292.These chassis ground pads 290 and 292 are electrically connected to thechassis ground plane 274. The metal faceplate 174 of the circuit card110 mounts to holes within the chassis ground pads 290 and 292 andmetal-to-metal contact is established between the chassis ground pads290, 292 and the faceplate 174. This metal-to-metal contact maintainsthe faceplate 174 at chassis ground.

While the invention has been particularly shown and described withreference to preferred embodiments thereof, it will be understood bythose skilled in the art that various other changes in the form anddetails may be made therein without departing from the spirit and scopeof the invention.

What is claimed is:
 1. A chassis for housing repeater cards, comprising:an inner housing with vertical sidewalls, a first surface, and a secondsurface, wherein the first surface and the second surface have a firstand second row of openings; one or more repeater cards positionedbetween the first surface and the second surface, the one or morerepeater cards having a DC—DC converter and a transceiver, the DC—DCconverter being positioned between a first opening of the first row ofthe first surface and a first opening of the first row of the secondsurface at least partially aligned with the first opening of the firstrow of the first surface, the transceiver being positioned between afirst opening of the second row of the first surface and a first openingof the second row of the second surface at least partially aligned withthe first opening of the second row of the first surface; a first meshstrip overlaying the first row of openings of the first surface; and asecond mesh strip overlaying the second row of openings of the firstsurface.
 2. The chassis of claim 1, further comprising: a solid area ofthe first surface located between a first edge of the first surface andthe first row of openings of the first surface; and a solid area of thesecond surface located between a first edge of the second surface andthe first row of openings of the second surface, the solid area of thesecond surface being at least partially aligned with the solid area ofthe first surface, wherein the one or more repeater cards have apolarized capacitor disposed between the solid area of the first surfaceand the solid area of the second surface.
 3. The chassis of claim 1,wherein the DC—DC converter has an epoxy case.
 4. The chassis of claim1, wherein the circuit board also has at least one relay, the at leastone relay having a power consumption less than or equal to 50milliwatts.
 5. The chassis of claim 4, wherein the circuit board alsohas a programmable logic device electrically linked to the at least onerelay, the programmable logic device having a power consumption lessthan or equal to 100 milliwatts when active.
 6. The chassis of claim 4,wherein the circuit board also has a faceplate abutting the first edgeof the first surface and the first edge of the second surface, thefaceplate having at least one light emitting diode, the at least onelight emitting diode being electrically linked to the at least one relayand being positioned between the solid area of the first surface and thesolid area of the second surface.
 7. The chassis of claim 1, furthercomprising: a mesh cover overlaying both the first mesh strip and thesecond mesh strip with a separation between the mesh cover and the firstand second mesh strips.
 8. The chassis of claim 1, wherein the innerhousing has a third surface separated from the second surface, thechassis further comprising at least one repeater card positioned betweenthe second surface and the third surface.
 9. The chassis of claim 8,wherein the third surface has a first row of openings and a second rowof openings and at least one repeater card is positioned between thesecond surface and the third surface, the at least one repeater cardhaving a DC—DC converter located between the first opening of the firstrow of the second surface and a first opening of the first row of thethird surface and the at least one repeater card having a transceiverlocated between a first opening of the second row of the second surfaceand a first opening of the second row of the third surface.
 10. Thechassis of claim 1, wherein the first surface and the second surfacehave a third row of openings positioned between the second row ofopenings of the first and second surfaces and a second edge of the firstand second surfaces that is opposite the first edge.